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Velo3D and PWR : Next generation heat exchangers
Heat exchangers are critical parts found in many different mechanical systems from home appliances to rocket engines . What makes them a unique design and manufacturing challenge lies in their primary function : small-scale heat exchangers demand complex internal geometries with leak-tight thin walls that separate hot and cold fluids with maximum surface area to enable the most efficient transfer of heat .
All text and images courtesy of Velo3D
Complex internal structures often require difficult and extensive post-processing operations when utilizing conventional AM technology . And oftentimes postprocessing these internal geometries can prove outright impossible . Meanwhile , traditional manufacturing methods struggle with complex internal geometries , limiting the use of optimal structures . Conventional additive manufacturing solutions also struggle with low angles , and often require support structures to produce the parts , which again demand extensive post-processing to remove , if they can be removed at all . These conventional AM systems also struggle with repeatability , so even when a design is successfully executed , replicating that success can be a major challenge .
In this case study we ’ ll look at PWR Advanced Cooling Technology , and how their partnership with Velo3D enabled a flexible solution for producing heat exchangers to meet the specifications of PWR ’ s high-profile clients in motorsport . This solution features a mix of Velo3D metal AM-produced parts and traditionally manufactured components .
Challenge In these highly competitive arenas , motorsport teams are looking for any advantage in performance to give them an edge . PWR is constantly on the lookout for new technologies and manufacturing methods to produce high-performance heat exchangers for their partners . Because of the nature of motorsport , PWR works in an extremely bespoke field ; rather than needing to produce hundreds or even dozens of heat exchangers , the company focuses on small batches of highly optimized parts . While heat exchangers are common and critical parts in automotive systems , they aren ’ t without their share of design and manufacturing challenges . Heat exchangers often rely on complex structures with leaktight thin walls to maximize the surface area of walls separating hot and cold fluids to dissipate and transfer heat . Conventional additive manufacturing processes struggle with the low angles required to achieve this level of
A water / oil heat exchanger featuring 220 micron turbulators and 320 micron leak-tight walls . This part was created by PWR and produced using Aluminum F357 .
16 Heat Exchanger World April 2023 www . heat-exchanger-world . com